Tobacco granules and method of producing tobacco granules

ABSTRACT

A smokeless tobacco product includes a plurality of orally disintegrable granules. Each granule has a core and at least one layer surrounding the core. The at least one layer includes tobacco particles and a binder. Also disclosed are methods of making tobacco granules that comprise a core and at least one layer having tobacco particles and a binder.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional and claims priority to U.S. applicationSer. No. 12/641,915 filed Dec. 18, 2009 which claims priority to U.S.Provisional Application Ser. No. 61/139,375 filed Dec. 19, 2008, both ofwhich are incorporated by reference in their entirety.

TECHNICAL FIELD

This invention relates to tobacco granules and a method of producing thesame.

BACKGROUND

Smokeless tobacco products are orally consumed without subjecting theproduct to combustion. These products are manufactured in a variety offorms including chewing tobacco, dry snuff and moist snuff. Generally,these types of products are made as follows with the steps being in noparticular order: cutting or grinding the tobacco into a suitable size;dipping or spraying the tobacco with a casing solution; partially dryingthe cased tobacco; holding the tobacco in containers for a period oftime; and packaging the tobacco. See, for example, U.S. Pat. Nos.4,528,993; 4,660,577; and 4,987,907.

Snuffs are often marked as either “dry” or “moist.” Dry snuffs aregenerally finely ground and have a typical moisture content of about 8%by volume. Moist snuffs can have a variety of particle sizes andtypically have a moisture content of about 40% to about 60% by weight.

Smokeless tobacco products are often treated with a variety of flavorsto provide a desirable taste experience. However, there remains a needfor smokeless tobacco products with novel flavor characteristics.

SUMMARY

This disclosure describes a smokeless tobacco product that includes aplurality of orally disintegrable granules. Each granule has a core andat least one layer surrounding the core. The at least one layer includestobacco particles and a binder. In some cases, the core and the at leastone layer are comprised of essentially the same composition of tobaccoparticles and binder.

The core can have a diameter of between 300 micrometers and 2millimeters. The cores can each have a core largest diameter and thetobacco particles can each have a core largest diameter that is not morethan ⅓ of the size of the core largest diameter. In some embodiments,each of the tobacco particles have a tobacco particle diameter that isno more than ⅕ the size of the core largest diameter. In someembodiments, the granules include non-tobacco cores. For example, thecore can include a carbohydrate, a water-soluble polymer, a flavorant, asalt, or a combination thereof. In other embodiments, the core caninclude tobacco. In some embodiments, the core can include tobaccopowder and a binder.

The tobacco particles can include a non-fermented tobacco. In someembodiments, the tobacco particles includes dry snuff. In someembodiments, the tobacco particles are cured tobacco particles preparedfrom tobacco plants having less than 20 μg of DVT per cm² of green leaftissue. The tobacco particles in the at least one layer can have anaverage diameter of less than 100 micrometers.

The binder can be selected from the group consisting of carboxymethylcellulose, hydroxypropyl cellulose, hydroxyethyl cellulose,hydroxypropyl methyl cellulose, methyl cellulose, konjac, collagen,inulin, soy protein, whey protein, casein, wheat gluten, carrageenan,alginates, propylene glycol alginate, xanthan, dextran, pullulan,curdlan, gellan, locust bean gum, guar gum, tara gum, gum tragacanth,pectin, agar, zein, karaya, gelatin, psyllium seed, chitin, chitosan,gum acacia, polyvinyl pyrrolidone, polyethylene oxide, polyvinylalcohol, and combinations thereof. In some embodiments, binder includesa hydroxyl-containing compound and a dextran or dextran derivative.

The granule can be generally spherical. In some embodiments, the granulehas a diameter of between 500 micrometers and 5 millimeters.

The at least one layer can further include a flavorant. For example, theflavorant can be selected from licorice, wintergreen, cherry and berrytype flavorants, DRAMBUIE brand liqueur, bourbon, scotch, whiskey,spearmint, peppermint, lavender, cinnamon, cardamon, apium graveolens,clove, cascarilla, nutmeg, sandalwood, bergamot, geranium, honeyessence, rose oil, vanilla, lemon oil, orange oil, Japanese mint,cassia, caraway, cognac, jasmin, chamomile, menthol, ylang-ylang, sage,fennel, piment, ginger, anise, coriander, coffee, mint oils from aspecies of the genus Mentha, and combinations thereof.

The granule can further include an additional layer concentricallysurrounding the core. The additional layer has a different compositionthan the at least one layer with regard to tobacco particleconcentration, type of tobacco particles, binder, flavorant, orcombination thereof. In some embodiments, the additional layer and theat least one layer comprise different flavorants. The additional layerand the at least one layer can also different concentrations of tobacco.

The smokeless tobacco product can consist of a plurality of thegranules. In other embodiments, the smokeless tobacco product includesadditional components. For example, the smokeless tobacco product caninclude a pouch holding the plurality of granules. In some embodiments,the pouch can include an edible film. In some embodiments, the pouchincludes a plurality of pores. In some embodiments, the smokelesstobacco product includes snuff and the plurality of granules aredispersed within the snuff. The snuff to granule ratio for the smokelesstobacco product can be between 1 and 90 weight/weight (wet).

The smokeless tobacco product can include a flavor profile having two ormore different flavors each having a peak flavor intensity beingperceptible at different times or concurrently during consumption. Forexample, the granules can each provide a flavor profile. A plurality ofgranules within a smokeless tobacco product can provide the same ordifferent flavor profiles.

The plurality of orally-disintegrable granules can each be produced byfluidizing a plurality of cores within a fluid bed processor having arotor, feeding a plurality of tobacco particles into the fluidized bed,and spraying a binder solution or suspension into the fluidized bedcontaining the fluidized cores. The binder solution or suspension caninclude a flavorant.

The core can further be coated by spraying a second binder solution orsuspension into the fluidized bed after spraying said first bindersolution to produce at least two concentric layers surrounding the core.Each of the binder solutions or suspensions can have a differentcomposition. For example, the first binder solution or suspension canhave a first flavorant and the second binder solution can have a secondflavorant different from the first flavorant. In some embodiments, thelayers are formed by altering the feed rate of tobacco into thefluidized bed to create adjacent layers having different concentrationsof tobacco.

This disclosure describes a process for making a tobacco product. Theprocess includes the steps of fluidizing a plurality of cores within afluid bed that includes a rotor, feeding tobacco particles into thefluid bed, spraying a coating solution or suspension that includes abinder and a solvent or suspension fluid into the fluid bed containingthe fluidized cores, and collecting granules formed after said sprayingand said feeding. Each of the formed granules include a core surroundedby at least one layer that includes the binder and a plurality oftobacco particles. The rotor can be a conical rotor.

The method can further include introducing a flavorant into the fluidbed containing the fluidized cores. In some embodiments, the coatingsolution or suspension includes a flavorant.

The feeding of the tobacco particles into the fluid bed can includeadding the tobacco particles to the coating solution or suspension sothat the tobacco particles are fed to the fluid bed during said sprayingof the coating solution or suspension. In some embodiments, the feedingof the tobacco particles can include feeding the tobacco particlesseparately from the spraying of the coating solution or suspension. Thefeeding step can be concurrent with said spraying step. In otherembodiments, the feeding step is prior to the spraying step. In otherembodiments, the feeding step is after said spraying step.

The method can also include changing the composition of the bindersolution or suspension during said spraying step to thereby produce twoor more concentric layers on said core such that each of the formedlayers have a different composition.

The method can also include feeding a plurality of starch particles, orany other filler material, into the fluidized bed. In some embodiments,the plurality of starch particles are mixed with the tobacco particlesand the starch particles and the tobacco particles are fed to the fluidbed in a common feeder.

The details of one or more embodiments are set forth in the accompanyingdrawings and the description below. Other features, objects, andadvantages will be apparent from the description and drawings, and fromthe claims.

DESCRIPTION OF DRAWINGS

FIGS. 1A-1D depict cross-sectional views of orally disintegrablegranules according to different embodiments.

FIGS. 2A and 2B depict flavor release profiles according to differentembodiments.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

This disclosure describes a smokeless tobacco product that includes aplurality of orally disintegrable granules 10. Examples of orallydisintegrable granules 10 are shown in FIGS. 1A, 1B, 1C, and 1D. Eachgranule has a core 12 and at least one layer 14 surrounding the core 12that contains tobacco particles 22 and a binder. In some cases, the coreand the at least one layer are the same or similar material. Eachgranule 10 can include more than one layer surrounding the core. Thus,the present disclosure describes granules having different arrangements,methods of making the granules, and smokeless tobacco products includingthese granules. It has been discovered that granules according to theinstant disclosure can confer unique flavor profiles on smokelesstobacco products.

I. Cores

Cores 12 have a diameter of between 300 micrometers and 2 millimeters.In some embodiments, the cores have a diameter of between 500micrometers and 1 millimeter (e.g., about 0.8 millimeter). In someembodiments, the cores 12 can include a carbohydrate, a water-solublepolymer, a flavorant, a salt, or a combination thereof. For example, acarbohydrate can include one or more sugars, such as glucose, lactose,or sucrose. For example, a water-soluble polymer can include starchesand cellulose fibers. In some embodiments, the cores 12 are granulatedsugar. Salts can include, for example, a citric acid salt or sodiumchloride. Flavorants used as a core can include, for example, herbs,spices or teas. In some embodiments, the core is tobacco free. In otherembodiments, the core can include tobacco. For example, the core caninclude a pressed core of tobacco powder. In other embodiments, such asshown in FIG. 1D, the core can include tobacco particles 22 within amatrix of other constituents. In some embodiments, the cores 12 caninclude sugar spheres formed from sucrose and starch, which can beobtained from the PAULAUR CORPORATION, located in Cranbury, N.J.

In some embodiments, the cores 12 can include gel cores including aplurality of constituents. Gel cores 12 can contain soluble or insolublegels. The amount of water retained in the gels depend on the propertiesdesired in the finished product. In some embodiments, as shown in FIG.1D, gel cores can include tobacco particles 22 dispersed within thecores. Exemplary gel binders for soluble and insoluble gels includekappa carrageenan, sodium alginate, carboxymethyl cellulose, gelatin,pectin, agar, and starches. Soluble gels can be formed by dissolving agel binder at an elevated temperature, e.g., kappa carrageenan at 180°F., and optionally adding other ingredients, such as a carbohydrate ortobacco particles to this solution while continuing vigorous mixing. Thehot mixture is then deposited into a mold to form a plurality of cores.Gelatin provides a weak gel at room temperature but firmness andstability can be increased by the addition of agar or starches. Othergelling binders may be used in a similar manner. Insoluble gels can beformed by the addition of a cross-linking agent to a pre-dissolvedsolution or slurry. The solution is deposited into a mold to form aplurality of cores and sets up through cooling and/or drying. In mostcases, it is necessary to maintain the solution at a high temperature,e.g., greater than 180° F., to prevent premature gelation prior todeposition into the mold. After the gel has set into a bead shape, thegel core can be further processed to form the granule 10 as is or befurther dried to a desired water content. Cross-linking agents caninclude potassium ions for carrageenan, calcium ions for alginates andlow methoxy pectins, and trivalent ions such as aluminum forcarboxymethyl cellulose. In insoluble gels (i.e., those that do notorally disintegrate), flavor compounds may leach out of the gel as it isheld or chewed in the mouth. For example, the gel beads disclosed inU.S. Patent Application Publication Nos. 2006/0191548 and 2008/0029110can be used as cores 12.

II. Layer(s)

Granule 10 further includes at least one layer 14 surrounding the core12. In some embodiments the core 12 and the at least one layer 14 arecomprised of the same or similar material. In some embodiments, as shownin FIGS. 1A and 1D, the granule 10 can include a single layer 14surrounding the core 12. Layer 14 includes a binder and tobaccoparticles 22. In other embodiments, the granule 12 includes a pluralityof layers. FIG. 1B depicts an embodiment including two layers 15 and 16,each including tobacco particles 22 and a binder. In some cases, thecore 12 further comprises tobacco. Layers 15 and 16 can differ incomposition. For example, layers 15 and 16 can differ in the type orconcentration of tobacco particles 22, the type of binder, and/or thetype or concentration of flavorant. FIG. 1C depicts an embodimentincluding three layers 17, 18, and 19. Layers 18 and 19 include tobaccoparticles 22 and a binder, while layer 17 does not include tobacco.Layers 18 and 19 can differ in the type or concentration of tobaccoparticles 22, the type of binder, and/or the type or concentration offlavorant. Layer 17 can include the same or a different flavorant fromlayers 18 and 19. In some embodiments, layer 17 can include other fillerconstituents, such as starch powders. In other embodiments, notspecifically shown, the granules 10 can include any number of layers inwhich the layers can each have the same or different constituents indifferent orders. For example, a granule could include six or morealternating layers in which every other layer includes tobaccoparticles, each successive layer includes a different flavorant, and thebinder varies between layers so different layers dissolve at differentrates.

Binders

Binders suitable for use in the layers described herein includeorally-compatible polymers, such as cellulosics (e.g., carboxymethylcellulose (CMC), hydroxypropyl cellulose (HPC), hydroxyethyl cellulose(HEC), hydroxypropyl methyl cellulose (HPMC), and methyl cellulose(MC)); natural polymers (e.g., starches and modified starches, konjac,collagen, inulin, soy protein, whey protein, casein, and wheat gluten);seaweed-derived polymers (e.g., carrageenan (kappa, iota, and lambda);alginates, (and propylene glycol alginate); microbial-derived polymers(e.g., xanthan, dextran, pullulan, curdlan, and gellan); extracts (e.g.,locust bean gum, guar gum, tara gum, gum tragacanth, pectin (lo methoxyand amidated), agar, zein, karaya, gelatin, psyllium seed, chitin, andchitosan); exudates (e.g., gum acacia (arabic) and shellac); and/orsynthetic polymers (e.g., polyvinyl pyrrolidone, polyethylene oxide, andpolyvinyl alcohol)). Other useful binders are known in the art, forexample, see Krochta et al. Food Technology, 1997, 51:61-74; GlicksmanFood Hydrocolloids CRC 1982; Krochta Edible Coatings and Films toImprove Food Quality Technomic 1994; Industrial Gums Academic 1993;Nussinovitch Water-Soluble Polymer Applications in Foods BlackwellScience 2003. In some embodiments, the binder can include hydroxypropylmethyl cellulose, which can be obtained from THE DOW CHEMICAL COMPANYunder the trade names METHOCEL™ HPMC E5, E15, and K4M.

Tobacco

At least one of the layers surrounding the core 12 of a granule 10contains a plurality of tobacco particles 22. The core 12 can optionallyinclude tobacco particles 22. The average diameter of such tobaccoparticles 22 is typically no more than ⅓ the size of the largestdiameter of the core 12. In some embodiments, the average tobaccoparticle 22 within a layer has an average diameter of no more than ⅕ thesize of the average diameter of the core 12. For example, the coreaverage diameter-to-tobacco particle average diameter ratio can be lessthan 10:1, less than 50:1, or less than 100:1. For example, the tobaccoparticles 22 can have an average diameter of less than 200 micrometers(e.g., an average tobacco particle diameter of between 10 micrometersand 40 micrometers, between 40 micrometers and 60 micrometers, between60 micrometers and 80 micrometers, between 80 micrometers and 120micrometers, between 120 micrometers and 160 micrometers, or between 160micrometers and 200 micrometers). In some embodiments, the averagetobacco particle diameter is between 20 micrometers and 40 micrometers(e.g., between 25 micrometers and 35 micrometers). In some embodiments,the tobacco particles 22 within the at least one layer have an averagediameter of less than 100 micrometers (e.g., about 80 micrometers). Forexample, the tobacco particles 22 can include micronized tobacco powder.The tobacco particles 22 can be sized or made to disintegrate in themouth (e.g., dissolve) or to give the perception of dissolvability(e.g., the tobacco does not produce a tactile experience in the mouth).For example, a micronized tobacco powder can have an average diameter of27 micrometers and a ninety-ninth percentile diameter of 120micrometers. Alternatively, the tobacco particles 22 may be sized ormade to provide a tactile experience in the mouth.

Depending on the desired characteristics, each layer can have a finaltobacco concentration ranging from 0 percent to 99 percent by weight(e.g., between 10 and 90 percent by weight, between 25 and 75 percent byweight, or between 40 and 60 percent by weight). For example, a layercan contain between 15 and 35 percent by weight tobacco (e.g., about 25percent by weight). In some embodiments, the plurality of granules caneach include at least one layer including greater than 20 percenttobacco (e.g., greater than 40 percent tobacco, greater than 60 percenttobacco, or greater than 80 percent tobacco).

The tobacco used in the granule 10, either as the tobacco particles 22in the layers and/or within the core 12, is a tobacco suitable for usein smokeless tobacco products. By “tobacco” it is meant a part, e.g.,leaves, flowers, and stems, of a member of the genus Nicotiana.Exemplary species of tobacco include N. rustica, N. tabacum, N.tomentosiformis, and N. sylvestris. Suitable tobaccos include fermentedand unfermented tobaccos, dark air-cured, dark fire cured, burley, fluecured, and cigar filler or wrapper, as well as the products from thewhole leaf stemming operation. For example, tobacco can be conditionedby heating, sweating and/or pasteurizing steps as described in U.S.Publication Nos. 2004/0118422 or 2005/0178398. Fermenting typically ischaracterized by high initial moisture content, heat generation, and a10 to 20% loss of dry weight. See, e.g., U.S. Pat. Nos. 4,528,993;4,660,577; 4,848,373; and 5,372,149. In addition to modifying the aromaof the leaf, fermentation can change either or both the color andtexture of a leaf. Also during the fermentation process, evolution gasescan be produced, oxygen can be taken up, the pH can change, and theamount of water retained can change. See, for example, U.S. PublicationNo. 2005/0178398 and Tso (1999, Chapter 1 in Tobacco, Production,Chemistry and Technology, Davis & Nielsen, eds., Blackwell Publishing,Oxford). Cured, or cured and fermented, tobacco can be further processed(e.g., cut, expanded, blended, milled or comminuted) prior toincorporating the tobacco into the granule 10. See, for example, U.S.Pat. Nos. 4,528,993; 4,660,577; and 4,987,907.

The tobacco can, in some embodiments, be prepared from plants havingless than 20 μg of DVT per cm² of green leaf tissue. For example, thetobacco particles can be selected from the tobaccos described in U.S.Patent Publication No. 2008/0209586, which is hereby incorporated byreference. Tobacco compositions containing tobacco from such low-DVTvarieties exhibits improved flavor characteristics in sensory panelevaluations when compared to tobacco or tobacco compositions that do nothave reduced levels of DVTs.

Flavorants

The cores and/or the one or more layers can include one or moreflavorants. Flavorants can produce a flavor release profile when thegranules 10 are orally consumed. The flavor release profile can becustomized by adjusting the ingredients and sizes of the layers. Forexample, by having a plurality of orally disintegrable granules eachhaving the same pattern of layers, a user consuming the granules canidentify a flavor profile, such as those described below.

Flavorants used within the granules 10 can be any flavorant known in theart. For example, suitable flavorants include wintergreen, cherry andberry type flavorants, various liqueurs and liquors such as DRAMBUIEbrand liqueur, bourbon, scotch, whiskey, spearmint, peppermint,lavender, cinnamon, cardamon, apium graveolens, clove, cascarilla,nutmeg, sandalwood, bergamot, geranium, honey essence, rose oil,vanilla, lemon oil, orange oil, Japanese mint, cassia, caraway, cognac,jasmin, chamomile, menthol, ylang-ylang, sage, fennel, piment, ginger,anise, coriander, coffee, and mint oils from a species of the genusMentha. Mint oils useful in the granules include spearmint andpeppermint.

Other Layer Constituents

Depending on the desired characteristics, each layer may also includefillers (e.g., starch, di-calcium phosphate, lactose, sorbitol,mannitol, and microcrystalline cellulose), soluble fiber (e.g.,FIBERSOL® from MATSUSHITA), calcium carbonate, dicalcium phosphate,calcium sulfate, and clays, lubricants (e.g., lecithin, stearic acid,hydrogenated vegetable oil, mineral oil, polyethylene glycol 4000-6000(PEG), sodium lauryl sulfate (SLS), glyceryl palmitostearate, sodiumbenzoate, sodium stearyl fumarate, talc, and stearates (e.g., Mg or K),and waxes (e.g., glycerol monostearate, propylene glycol monostearate,and acetylated monoglycerides)), plasticizers (e.g., glycerine,propylene glycol, polyethylene glycol, sorbitol, mannitol, triacetin,and 1,3 butane diol), stabilizers (e.g., ascorbic acid and monosterolcitrate, BHT, or BHA), artificial sweeteners (e.g., sucralose,saccharin, and aspartame), disintegrating agents (e.g., starch, sodiumstarch glycolate, cross caramellose, cross linked PVP), or othercompounds (e.g., vegetable oils, surfactants, and preservatives). Somecompounds display functional attributes that fall into more than one ofthese categories. For example, propylene glycol can act as both aplasticizer and a lubricant and sorbitol can act as both a filler and aplasticizer.

The layers can also include remnants of food grade solvent or suspensionfluid used during a coating process. For example, the food grade solventor suspension fluid can allow for the spraying of the binder within afluid bed processor. A majority of the solvent or suspension fluid isgenerally evaporated during the coating process to form the layers ofthe granule, but trace amounts can remain. The solvent or suspensionfluid can have a latent heat of vaporization of at least 300 KJ/Kg. Insome embodiments, the solvent or suspension fluid can have a latent heatof vaporization of between 500 KJ/Kg and 2500 KJ/Kg (e.g., between 800and 2300 KJ/Kg, between 500 and 1300 KJ/Kg, or between 1300 and 2500KJ/Kg). For example, the latent heat of vaporization of ethanol is 841KJ/Kg and the latent heat of vaporization of water is 2260 KJ/Kg.Typical solvents or suspension fluids include water, ethanol, methanol,isopropynol, acetone, and combinations thereof.

III. Smokeless Tobacco Products

A plurality of granules 10 can themselves be a smokeless tobacco productor can be incorporated with other materials into a smokeless tobaccoproduct. Smokeless tobacco compositions incorporating a plurality ofgranules 10 can contain, without limitation, moist or dry smokelesstobaccos including snus-style products, loose tobacco in a pouch or packor snuff tobaccos. See, e.g., U.S. Patent Publication Nos. 2005/0244521and 2006/0191548 for descriptions of a number of smokeless tobaccocompositions. Smokeless tobacco compositions having granules 10 mixedtherein can provide the smokeless tobacco composition with a desiredflavor release profile. The snuff-to-granule ratio for the smokelesstobacco product is not limited. In some embodiments, thesnuff-to-granule ratio is between 1 and 90 weight/weight (wet). Forexample, the snuff to granule ratio can be between 30 and 65weight/weight (wet).

Granules 10 can also be packaged with other smokeless tobacco productswithout the granules 10 being intermixed with the other smokelesstobacco products. For example, granules 10 can be packaged along withother smokeless tobacco products in a divided container, with thegranules 10 in a different segment of the divided container. A dividedcontainer can allow a user to experience the granules alone, the othersmokeless tobacco product(s) alone, or a combination of the productstogether. A plurality of different types of granules 10 could also beincluded in different sections of a divided container. In otherembodiments, the granules 10 are encapsulated in one or more blistersinside the container of a smokeless tobacco product to allow for a userselectively increase or alter the flavor of the smokeless tobaccoproduct. For example, a user can have moist smokeless tobacco productcontainer with multiple blister packs inside the lid, each blister packhaving granules providing a different flavor profile, thus the user canelect a particular flavor or combination of flavors or elect to not useany flavors at all. Furthermore, granules can be added to increase theflavor intensity after an initial use.

A plurality of the granules can, in some embodiments, be sold alone inpackages for direct oral consumption. For example, granules 10 can bepackaged loosely in sugar type paper packages, slide fastener plasticbags, blister packs, portion-control dispensers (e.g., like a peppergrinder), straws or tubes with sealed ends, and box-like containers. Forexample, a container can have a shape and size approximating that of acigarette pack or cigarette lighter. In some embodiments, a plurality ofgranules 10 can be packaged in an open or highly porous wrappingmaterial, (e.g., fabrics, paper or plastic films), with or withoutadditional smokeless tobacco product. In other embodiments, a pluralityof granules 10 can be packaged in a consumable package, (e.g., a pouchmade of a pair of edible film strips sealed or adhered together alongtheir edges). For example, the edible film used to produce a consumablepackage could be of the type described in U.S. Patent Publication No.2005/0089548, which is hereby incorporated by reference. A plurality ofdifferent types of granules 10 can be packaged together. In someembodiments, a first plurality of granules 10 having a first flavorprofile are packaged with a second plurality of granules 10 having asecond and different flavor profile. The first and second pluralities ofgranules can be visually differentiated by have different exteriorcolors. Differently granule groups can be mixed or segregated.

Mixtures of granules, with or without other smokeless tobaccocompositions or other ingredients, can be molded, extruded, pressed, orotherwise formed into shaped smokeless tobacco pieces. In someembodiments, mixtures of granules, with or without other smokelesstobacco compositions or other ingredients, can be compressed to form atablet or disc. A tablet could then be packaged and/or dispensed in adispenser that includes stacked tablets and individually pushes out onetablet at a time upon activation of a dispensing mechanism. For example,granules 10 can be included in a non-dissolvable tobacco tablet or discwhere the granules 10 are dispersed within a matrix of non-dissolvablesmokeless tobacco material. A smokeless tobacco tablet or disc can alsobe made entirely of granules 10 pressed together. In other embodiments,a tablet could include a granule 10 layer on one side and a smoothtexture of another smokeless tobacco product on the reverse side toprovide a texture interplay. Granules 10 can also be pressed into a baror stick shape. Pluralities of granules 10 can also be pressed intoirregular cluster shapes. In some embodiments, clusters of granules 10can include a lipid coating (e.g., steric acid). Granules 10 can also bepressed into a flexible tape, which can be rolled up for distribution.The granules can also be molded around preformed items, such astoothpicks, pretzel sticks, other small cylinder shapes, or a flexiblecarrier. For example, granules 10 can be molded into pearl-like beads ona string to form a tobacco granule necklace.

Granules 10 can also include outer coatings that can give the granules10 desired bulk properties. For example, the outer coating can include asticky coating that allows a user to pinch a plurality of granules 10together for consumption. In other embodiments, granules 10 can includean outer coating that inhibits bonding between granules 10, such thatthe granules 10 will easily flow. In other embodiments, the materialsused for the granules 10 can be selected to impart a desiredcompressibility giving a desired mouth feel. For example, in someembodiments, the granules 10 can have a compressibility approximatingthat of a tapioca ball. In other embodiments, the granules can beincompressible and designed to be crunched in a user's mouth.

Granules 10 can also be included with non-tobacco products. For example,granules 10 can be combined with a chewable gum to provide taste and/ortexture to the gum. In some embodiments, the gum can include additionalsmokeless tobacco products. In other embodiments, granules 10 can bepackaged along with a preformed object that can be dipped into a sectionof the packaging having granules 10 to coat the preformed object withgranules 10 for consumption. The preformed object can be made of anumber of consumable or non-consumable materials. For example, thepreformed object can be a lipid soft tab or a pressed sugar stick. Insome embodiments, the preformed object can include other smokelesstobacco products. In other embodiments, granules 10 can be includedwithin crystallized confectionaries, such as crystallized maple syrup.Granules 10 can also be included in a bubble tea. For example, granules10 can either be present in a bubble tea along with or replacing tapiocaballs and can have a compressibility approximating that of a tapiocaball.

A plurality of granules 10 can also be sintered together to form aporous matrix. The porous matrix can have a shape adapted to be whollyreceived in the mouth, e.g., between the lip and the gums. For example,a plurality of granules 10 can be formed into a desired shape and heatedsuch that adjacent granules become bonded together. The process caninclude heating the plurality of granules 10 to a temperature below themelting point of the outer surface of the granules 10. The plurality ofgranules 10 can also be sintered in the presence of other tobaccomaterials, such as moist or dry smokeless tobaccos. The additionaltobacco materials can be in powdered form, granular form, or provided aselongated cut tobacco. The other tobacco material can then be present inthe resulting pores between adjacent sintered granules. The granules 10can also include a polymeric outer surface. A polymeric outer surfacecan include one or more of the following polymer materials: acetals,acrylics such as polymethylmethacrylate and polyacrylonitrile, alkyds,polymer alloys, allyls such as diallyl phthalate and diallylisophthalate, amines such as urea, formaldehyde, and melamineformaldehyde, cellulosics such as cellulose acetate, cellulosetriacetate, cellulose nitrate, ethyl cellulose, cellulose acetatepropionate, cellulose acetate butyrate, hydroxypropyl cellulose,cellophane and rayon, chlorinated polyether, coumarone-indene, epoxy,fluorocarbons such as PTFE, FEP, PFA, PCTFE, ECTFE, ETFE, PVDF, and PVF,furan, hydrocarbon resins, nitrile resins, polyaryl ether, polyarylsulfone, phenol-aralkyl, phenolic, polyamide (nylon), poly(amide-imide), polyaryl ether, polycarbonate, polyesters such asaromatic polyesters, thermoplastic polyester, PBT, PTMT, PET andunsaturated polyesters such as SMC and BMC, polyimides such asthermoplastic polyimide and thermoset polyimide, polymethyl pentene,polyolefins such as LDPE, LLDPE, HDPE, and UHMWPE, polypropylene,inomers such as PD and poly allomers, polyphenylene oxide, polyphenylenesulfide, polyurethanes, poly p-xylylene, silicones such as siliconefluids and elastomers, rigid silicones, styrenes such as PS, ADS, SAN,styrene butadiene lattices, and styrene based polymers, sulfones such aspolysulfone, polyether sulfone and polyphenyl sulfones, thermoplasticelastomers, and vinyls such as PVC, polyvinyl acetate, polyvinylidenechloride, polyvinyl alcohol, polyvinyl butyrate, polyvinyl formal,propylene-vinyl chloride copolymer, ethylvinyl acetate, and polyvinylcarbazole. In addition, the polymeric outer surface can be colored,resulting in a colored sintered smokeless tobacco product containinggranules 10 and optionally other smokeless tobacco materials betweenadjacent sintered granules. For example, a plurality of granules 10,each including a core and one or more layers including flavorants andtobacco, can be each be coated with polyethylene. The polyethylenecoated granules can then be sintered together into a flat rectangularshape for placement between the lip and the gums. The sintering processcan be preformed in the presence of powder tobacco. Descriptions ofsintering processes can be found in Provisional U.S. Patent ApplicationNo. 61/141,968, filed Dec. 18, 2008, which is hereby incorporated byreference.

IV. Granule Formation

The process of forming the granules can vary depending on the specificequipment used, the specific core material, and the materials formingthe one or more layers. In some embodiments, the layers are addedsuccessively in a single apparatus used for granule formation. Forexample, cores can be fluidized and the constituents of each layer addedin successive steps, changing the compositions and/or feed rates of eachconstituent to tailor the composition of each successive layer.

An apparatus that is suitable for granule formation is a fluid bedprocessor that contains a rotating plate (“rotor”) inside the fluid bed.Cores are fluidized by the rotation of the rotor and by the flow of airthrough the annular clearance between the rotor and the vessel wall. Insome embodiments, the rotor has a conical upper surface. The granules 10can be formed by fluidizing a plurality of preformed cores 12 within thefluid bed rotor processor by rotating the rotor and passing air throughthe annular clearance between the rotor and the vessel wall.

The components for each layer are then fed to the fluid bed rotorprocessor to form the one or more layers. The components include atleast a binder and, for at least one layer, tobacco particles. Thebinder can be dissolved or suspended in a food grade solvent orsuspension fluid, which can be evaporated during the coating process.The coating solution or suspension can be sprayed by tangential sprayguns. A spray nozzle is suitable for introduce a coating solution orsuspension into the fluid bed rotor processor. The spray nozzle can be acurrently available nozzle which provides adequate atomization of thecoating solution. In some embodiments, the one or more spray nozzles caninclude tangential spray guns. In addition to the binder and a foodgrade solvent or suspension fluid, the coating solution or suspensioncan include one or more flavorants. In other embodiments, flavorants canbe separately added to the apparatus used for granule formation. Thecoating solution or suspension can be sprayed into the apparatus usedfor granule formation using one or more spray nozzles. In someembodiments, tobacco particles and/or other dry ingredients can bepremixed with the coating solution or suspension and fed sprayed intothe fluid bed rotor processor as part of the coating solution orsuspension.

Dry ingredients can be separately fed to the fluid bed rotor processor.The dry ingredients include the tobacco particles and other particulateingredients, e.g., starch may be included in one or more layers. Theother dry particulate ingredients can serve as fillers, flavorants,disintegrants, binders, and/or colorants to produce layers withouttobacco particles (e.g., layer 17 of FIG. 1C). A volumetric powderfeeding unit is suitable for feeding the dry ingredients to the fluidbed rotor processor. The dry ingredients can be fed to the fluid bedrotor processor simultaneously with the spraying of the coating solutionor suspension. The spraying of the coating solution or suspension andthe feeding of the tobacco particles or other dry particulate can alsobe intermittent.

A fluid bed rotor processor allows for a uniform distribution of thetobacco particles within the core and/or each layer, efficient drying ofthe coating solution or suspension to form each layer, and the abilityto apply successive layers in a single operation within the fluid bedrotor processor. The processor can also yield granules having a desireduniformity and conformity in granule size and layer thickness. Byvarying the rates and/or compositions of the tobacco particles and/orthe coating solution or suspension, a plurality of layers each havingdifferent compositions can be formed on the plurality of cores 12, whichcan provide a desired flavor profile, such as those described below. Thecore can also contain tobacco particles. For example, a core includingtobacco powder and a binder can be produced using the fluid bed rotorprocessor in a first step prior to adding layers using the fluid bedrotor processor. The coating conditions can also be controlled byvarying the rotor speed, the inlet air temperature, humidity, and/or theair flow rate. The rotor can rotate at a speed of between 50 and 500revolutions per minute (e.g., between 185 and 325 revolutions perminute). The amount of air passing through the annular clearance can bebetween 5 and 100 cubic feet per minute (e.g., between 10 and 35 cubicfeet per minute). The temperature of air passing through the annularclearance can be between 10 and 80° C. (e.g., between 20 and 70° C.).The speed of rotation of the rotor and/or the amount and/or temperatureof air passing through the annular clearance can be varied during thegranule formation process. An example of a fluid bed rotor processor issold by VECTOR CORPORATION (Sloan, Iowa) under the trade name GRANUREX®(e.g., the GXR30). The GRANUREX® processor includes a cylindrical vesseland a conical rotor at the base, which rotates around the central axis.Fluid bed processors having a rotor, in particular a conical rotor, canproduce granules having more uniform layers than fluid bed processorsthat lack a rotor.

V. Flavor Profile

Granules 10 can be formulated to release their components as desired toresult in a release profile when a plurality of the granules 10, eachhaving the same arrangement, are orally consumed. The granules 10 can bemade in a process that produces a plurality of granules having layers ofsufficient uniformity and consistency to control the order of componentrelease when the granules are orally consumed. Furthermore, the rate ofcomponent release can be controlled by the composition of each layerand/or the core. These features, either alone or in combination, canresult in a plurality of the granules providing, when orally consumed, adesired flavor profile. For example, as shown in FIG. 2A, an adultconsumer consuming a plurality of granules 10 having the approximatestructure of the granule 10 of FIG. 1A will first detect a firstFlavorant A, located within layer 14, for a first period of time. Then,as the layers 14 become fully consumed, the adult consumer will begin todetect a second Flavorant B, located within core 12, for a second periodof time until the cores 12 are fully consumed.

Granules 10 can include layers having different disintegration rates.Fast release layers typically disintegrate in under 1 minute and mostpreferably, in 30 seconds or less, e.g., less than 30 s, 25 s, 20 s, 15s, 10 s, 5 s, 4 s, 3 s, 2 s, or 1 s. Disintegration can occur bydissolution, melting, enzymatic or other chemical degradation, and/ordisruption of the interaction between the binder and tobacco. The binderor tobacco itself may similarly disintegrate. The amount of timerequired for a composition to disintegrate may be controlled by varyingthe thickness of the layer and is dependent upon the type of binder,other additives, and the way the granule is consumed. The flavor profilecan also be controlled by the concentration and/or intensity of eachflavorant in each layer. In some embodiments, granules 10 can includeone or more layers having a concentration of at least 50 weight percentflavorant (e.g., 60, 70, 80, or 90 weight percent).

FIG. 2B depicts one possible flavor release profile for a plurality ofgranules having the approximate structure of the granule 10 of FIG. 2B.As shown, an adult consumer can first experience a flavor spike of afirst flavor in the rapidly dissolving layer 15 along the outer surfaceof the granule 10. A rapidly dissolving outer layer can also provide theadult consumer with an initial burst of tobacco. The second layer 16 canthen provide the adult consumer with a second flavor of Flavorant A witha more sustained release of both flavorant and tobacco. Finally, as thelayer 16 becomes fully consumed, the adult consumer can then experiencea third flavor of Flavorant B, present in the core 12. In otherembodiments, the core 12 can provide a high intensity and long lastingflavor. In still other embodiments, a flavor spike can produced by athin layer having a very high concentration of flavorant, with orwithout the presence of tobacco.

Granules 10 can be formulated to have different total dissolution times.The total dissolution time of a granule is based upon, inter alia, thenumber of layers, the disintegration rates of those layers, and the sizeand composition of the core. The total dissolution time for a granulecan be between 5 seconds and 15 minutes. In some embodiments, thegranules 10 have a rapid total dissolution time of between 5 seconds and30 seconds (e.g., between 5 seconds and 10 seconds, between 10 secondsand 20 seconds, or between 20 seconds and 30 seconds). In someembodiments, the granules have a prolonged total dissolution time ofbetween 2 minutes and 15 minutes (e.g., between 2 minutes and 4 minutes,between 4 minutes and 8 minutes, or between 8 minutes and 15 minutes).In some embodiments, the granules 10 have an intermediate totaldissolution time of between 30 seconds and 2 minutes (e.g., between 30seconds and 45 seconds, between 45 seconds and 75 seconds, or between 75seconds and 2 minutes).

The flavor release profile and the flavor characteristics of thegranules 10 or a tobacco composition containing the granules 10 can beevaluated by a sensory panel using techniques known in the art. Forexample, panelists can be trained and used to evaluate the flavorcharacteristics of tobaccos according to Grub (1998, In Flavourings byZiegler & Ziegler, eds., pp. 513-524, Wiley-VCH Verlag GmbH, Weinheim,Germany); Tamura et al. (1989, Agric. Biol. Chem., 53, 1625-1633); andDunkel et al. (2007, J. Agric. Food Chem., 55:6712-9). In addition,North Carolina State University Sensory Service Center, The Institutefor Sensory Research at Syracuse University, Ohio State UniversitySensory Science Group, the Sensory Laboratory at Oregon State Universityand Monell Chemical Senses Center in Philadelphia have sensory testingfacilities and offer various sensory evaluation services. For example,sensory panel participants can evaluate the intensity of differentdetected flavorants on a scale of 1 to 10 as a function of time andchart those intensities in charts similar to those shown in FIGS. 2A and2B. Granules described herein have desirable flavor profiles, e.g.,first and second flavorants having flavor intensity peaks in which theflavor intensity of the first flavor is at less than 50% of its peakintensity at the time of the second flavor peak intensity or a firstflavorant having a flavor intensity peak at a time prior to thedetection of a second flavor.

In general, the delivery of desirable flavor properties is nearlylimitless and includes one or more flavorants provided in the core or inone or more layers having the same, similar, or variable dissolutiontimes. Flavor intensity profiles can have intensity peaks that aresequential, overlapping, or concomitant in nature. In some embodimentsgranules 10 are provided that offer differing flavor release profilesone from the others in that one or more granules release the same ordifferent flavors at the same or differing time points. The use ofgranules or groups of granules each having different flavor profiles canallow for the mixing and matching of granules having different flavorprofiles to yield customizable smokeless tobacco products. For example,one group of granules can provide a burst release of mint flavor, asecond group of granules can include a delayed release of cinnamonflavor, and a third group of granules can provide an intermittentrelease of vanilla; granules from these groups could be selectivelycombined (e.g., burst of mint with intermittent vanilla, mint withcinnamon, cinnamon with intermittent vanilla, or all three flavors) invarying amounts to yield a desired flavor profile for the overallsmokeless tobacco product. The use of the granules can also improve theflavor stability by protecting flavorants from possibly causticenvironments until the smokeless tobacco product is consumed.

The invention will be further described in the following examples, whichdo not limit the scope of the invention described in the claims.

VI. Examples

A VECTOR GRANUREX® GXR30 fluid bed rotor processor was used to makemint-flavored granules. Eight batches were processed, using componentsshown in Table I.

TABLE 1 Batch 1 Batch 2 Batch 3 Batch 4 Batch 5 Batch 6 Batch 7 Batch 8Ingredients dw % g dw % g dw % g dw % g dw % g dw % g dw % g dw % dSugar Beads 69 2000 65.5 2000 63.93 2000 55.89 1500 62.23 1500 — — 45.11500 — — Starch — — — — — — — — 16.27 392.3 23.46 750 23.4 779 42.291009.5 Tobacco — — — — — — — — — — 46.9 1500 — — — — Beads Tobacco 30869 30 916 28.78 900 33.54 900 16.27 392.3 23.46 750 23.4 779 52.37 1250HPMC (E5) — — 2.5 76.3 3.18 99.34 — — 2.7 65.05 — — 5.56 184.91 3.8992.75 HPMC (E15) — — — — — — 7.53 201.96 — — — — — — — — HPMC — — — — —— — — — — 4.21 134.72 — — — — (K4M) Sucralose — — — — 0.19 6.03 0.174.65 0.16 3.95 0.12 3.85 0.16 5.29 0.094 2.25 Pre-hydrated — — — — 1.1235 1.02 27.36 0.96 23.24 0.75 24.1 0.99 33.02 0.56 13.25 Gum Mint Flavor1 28.98 2 61.1 2.27 71 1.02 27.36 0.96 23.24 0.75 24.1 0.99 33.02 0.5613.25 Sodium — — — — 0.51 16 0.46 12.3 0.43 10.45 0.34 10.83 0.45 14.810.25 5.96 Chloride Water — 1500 — 500 — 1500 — 489.6 — 780 — 1530 — 2100— 834.75 Dehydrated — — — — — — — 1836 — — — — — — — — Alcohol (ETI07)Ispropyl — — — 1500 — — — — — — — — — — — — Alcohol (IPA)

Tobacco from plants having less than 20 μg of DVT per cm² of green leaftissue was aged, fermented, pre-conditioned, cased, and milled toproduce particles with an average diameter of 27 micrometers and aninety-ninth percentile diameter of 120 micrometers. It should be notedthat the moisture content of the tobacco, as it is processed, ismonitored from time to time and adjusted by one or more drying steps.Hydroxypropyl methyl cellulose (METHOCEL™ HPMC E5, E15, and K4M) wasobtained from THE DOW CHEMICAL COMPANY. Sucralose sold under the tradename SPLENDA® was also obtained. Sugar spherical cores and starch werefrom the PAULAUR CORPORATION of Cranbury, N.J. PRE-HYDRATED® Gum Arabic(gum arabic/gum acacia) was from TIC GUMS Inc. Sodium chloride salt wasfrom CARGILL. Starch (SPRESS® B820) was from the GRAIN PROCESSINGCORPORATION. Dehydrated alcohol (ET107) and isopropyl alcohol (IPA) werefrom SPECTRUM CHEMICALS & LABORATORY PRODUCTS.

Experiments were carried out using a VECTOR GRANUREX® GXR30 fluid bedrotor system, which is capable of drying, coating, granulating andpowder layering. Batches 1 through 5 used sugar spherical cores havingan average diameter of between 710 to 850 micrometers. Batch 6 furthercoated the granules of batch 5. Batch 7 used sugar spherical coreshaving an average diameter of between 850 and 1000 micrometers. The sizeratio between the tobacco particles and cores was greater than 1:100.For batches 1-7, cores were poured into the product container, thenintermittently sprayed with a nebulized coating solution, via atangential spray gun. The tobacco particles were fed to the VECTORGRANUREX® GXR30 fluid bed rotor system using a K-TRON screwpowder-feeding unit made by COPERION.

Batch 1 attempted to coat sugar cores with tobacco particles using waterwithout binder. Mint flavor was also added. The experiment of batch 1was aborted after ten minutes once it was determined that it did notcreate tobacco granules.

Batch 2 attempted to coat sugar cores with tobacco powder using acoating solution of IPA containing HPMC E5. Mint flavor was also added.Water was added after forty minutes upon determining that IPA could notsatisfactorily dissolve the binding agent. The experiment was abortedafter seventy minutes due to insufficient binding.

Batch 3 used HPMC (E5) and water as binder and solvent, respectively,with salt, sucralose, and mint flavor added to adjust taste, andpre-hydrated gum to promote suspension of the hydrophobic mint flavor insolution. After the spherical sugar cores had been loaded into theproduct container and the system preheated to 22.4° Celsius, a screwfeeding unit with a special eductor, designed by VECTOR, was used tocontain and direct tobacco powder into the rotor processor. Totalcoating solution weight was 1727 grams, of which 1180 grams were used topowder layer 900 grams of dry tobacco powder—giving a powder-to-bindersolution ratio of 1:1.31. The remainder of the coating solution wasapplied after all tobacco particles had been fed into the processor.Batch 3 granules had a total dissolution time of about 15 seconds.

Batch 4 used HPMC (E15) as the binder and 3000 grams of ET107 as thesolvent. 800 grams of water were added to the coating solution after tenminutes. In all, 900 grams of tobacco particles were layered with 1300grams of coating solution—a ratio of 1:1.44. An additional 1300 grams ofcoating solution was applied after all tobacco particles had been fedinto the processor; 1647 grams of solution remained unused. Batch 4granules had a total dissolution time of about 40 seconds.

Batch 5 used HPMC (E5) as a binder and water as the solvent. About 785grams of a 1:1 mixture of tobacco and starch was layered at an increasedpowder feeding rate of 1000 grams/hour, using 900 grams of solution fora particulate to coating solution ratio of 1:1.15. Batch 5 granules hada total dissolution time of about 30 seconds.

Batch 6 used the granules of batch 5 as a starting core and added asecond layer. Batch 6 used HPMC (K4M) as a binder and water as thesolvent. 1500 grams of a starch and tobacco mixture having a 1:1 ratiowas layered using 1442 grams of the coating solution for apowder-to-solution ratio of 0.96:1. An additional 268 grams of solutionwere applied to the granules after powder layering. The powder feedingrate was increased, relative to other batches, to between 1250 and 2000grams/hour. Batch 6 granules had an average total dissolution time ofabout 300 seconds.

In batch 7, 300 grams of flavored coating solution was applied to thesugar cores prior to powder layering. 1560 grams of powder with a 1:1tobacco-to-starch ratio was layered using 2260 grams of water-basedcoating solution—a ratio of 1:1.45. An additional 100 grams of solutionwas applied after powder layering. Batch 7 granules had an average totaldissolution time of about 240 seconds.

In batch 8, starch and tobacco powder were loaded into the productcontainer. Granulation was initiated once the system reached a pre-heattemperature of 30° C., using HPMC (E5) as binder and water as solvent.In batch 8, the tobacco powder and/or the starch initiates the granuleformation and thus act as cores. Batch 8 granules had an average totaldissolution time of less than 5 seconds. In other embodiments, thegranules produced in batch 8 can further be used as the cores and layersadded to the granule of batch 8.

The experiments discussed above resulted in six different types oftobacco granules. Characteristics of the different types of granules areshown in Table II.

TABLE II Resulting Resulting Average Average Product Product disso- CoreSize Size D50 Size D99 lution Batch (microns) (microns) (microns) Bindertime¹ 1 800 N/A N/A None N/A 2 800 N/A N/A HPMC (E5) N/A 3 800 1074 1752HPMC (E5) 15 4 800 1123 1180  HPMC (E15) 40 5 800 1231 1904 HPMC (E5) 306 800 1348 1950  HPMC (K4M) 300 7 1000 1336 1947 HPMC (E5) 240 8 27 946946 HPMC (E5) <5 ¹Dissolution time is the average approximate time inseconds that was required to completely dissolve a granule when orallysampled.

The granules produced in each batch were taste tested by experiencedtesters. The average dissolution time was measured by the experiencedtesters. HPMC (E5) was used as a binder to confer a rapid flavorrelease, HPMC (E15) was used as a binder to confer a relatively moderaterate of flavor release, and HPMC (K4M) was used as a binder to confer arelatively slow flavor release. Batch 4 granules contained an additionalouter layer designed to decrease the tobacco release rate and extendflavor release duration. The batch 5 granules were intended to have aslower dissolution rate, which was achieved. Batch 6 granules wereintended to have a slow initial disintegration of the outer layer,followed by a more rapid disintegration of the inner layer. The largeraverage granule size contributed to the longer average dissolution time.The large core size and relatively thick layers of batch 7 granules letto a relatively longer average dissolution time. In addition, batch 7granules had a layer intended to generate a flavor spike toward the endof granule disintegration. However, the amount of coating solution usedappeared to be insufficient to produce the desired flavor effect.

The granules made during these experiments were stored for ten months atroom temperature. No noticeable change in flavor, pH or percentage ofoven volatiles was observed.

A number of embodiments have been described. Nevertheless, it will beunderstood that various modifications may be made without departing fromthe spirit and scope of this disclosure. For example, some smokelesstobacco products can include granules having a rapid release bindingagent can be used in the outer layer for immediate satisfaction, then aslow release agent in the intermediate layers for sustained flavor, anda rapid release agent in the core or immediately surrounding the corefor a final flavor flash. Still other smokeless tobacco products caninclude combinations of granules having different flavorant, flavorrelease, and disintegration properties. Accordingly, other embodimentsare within the scope of the following claims.

What is claimed is:
 1. A process for making a smokeless tobacco productcomprising: fluidizing a plurality of cores within a fluid bedprocessor, the cores having a first average diameter, the fluid bedprocessor including a rotor, each core of the plurality of coresincluding tobacco; forming a first layer by feeding a plurality oftobacco particles into the fluid bed processor at a first rate, theplurality of tobacco particles having a second average diameter lessthan or equal to ⅕ the first average diameter; spraying a first coatingcomposition into the fluid bed processor, the first coating compositionbeing a solution or suspension, the first coating composition including(i) a binder and (ii) a solvent or suspension fluid; forming a secondlayer by varying a feed rate of the tobacco particles from the firstrate to a second rate different than the first rate; and collecting aplurality of granules formed after the spraying, the forming the firstlayer, and the forming the second layer, each granule of the pluralityof granules including a core of the plurality of cores surrounded by thefirst layer having a first tobacco concentration and including thebinder and a first portion of the plurality of tobacco particles and thesecond layer having a second concentration of tobacco particlesdifferent from the first concentration and including the binder and asecond portion the plurality of tobacco particles, the first layer andthe second layer being concentric.
 2. The process of claim 1, whereinthe rotor comprises a conical rotor.
 3. The process of claim 1, furthercomprising: introducing a flavorant into the fluid bed processor.
 4. Theprocess of claim 1, wherein the first coating composition furthercomprises a flavorant.
 5. The process of claim 1, wherein the firstcoating composition further comprises the plurality of tobaccoparticles, and the feeding and the spraying are performed concurrently.6. The process of claim 1, wherein the feeding and the spraying areperformed concurrently.
 7. The process of claim 1, wherein the feedingis performed prior to the spraying.
 8. The process of claim 1, whereinthe feeding is performed after the spraying.
 9. The process of claim 1,further comprising: feeding a plurality of starch particles into thefluid bed processor.
 10. The process of claim 9, further comprising:mixing the plurality of starch particles with the plurality of tobaccoparticles to create a mixture prior to the feeding the plurality ofstarch particles and the feeding the plurality of tobacco particles; anddisposing the mixture in a common feeder prior to the feeding theplurality of starch particles and the feeding the plurality of tobaccoparticles.
 11. The process of claim 1, wherein the fluid bed processorcomprises a vessel having a wall, and the rotor is disposed inside thevessel and spaced apart from the wall to define an annular clearance.12. The process of claim 11, wherein the fluidizing comprisesconcurrently rotating the rotor and flowing air through the annularclearance.
 13. The process of claim 12, wherein the rotating isperformed at a rotor speed ranging from 50 revolutions per minute (RPM)to 500 RPM.
 14. The process of claim 12, wherein the flowing isperformed at a flow rate ranging from 5 cubic feet per minute (CFM) to100 CFM.
 15. The process of claim 12, wherein the air has a temperatureranging from 10° C. to 80° C.
 16. The process of claim 1, wherein thesmokeless tobacco product includes a flavor profile including twodifferent flavors configured to have peak flavor intensities beingperceptible at different times during consumption in a standardizedsensory evaluation.
 17. The process of claim 16, wherein the twodifferent flavors include a first flavorant in the first layer and asecond flavorant in the second layer.